Site Selection & Area
Allocation
1
Maximizing Existing Facilities
Consider the Following Areas for Cube
Utilization:
 Under the floor. Basements are the biggest
user of under floor space. Evaluate using for
walkways (between buildings) and utility
runs.
 Overhead. Various usages.
 Roof. The roof could be used for
recreational endeavors, central A/C units, silo
for material storage, water towers, etc. Get it
off the floor.
2
Maximizing Existing Facilities


Truss level. A truss is a rafter.
Depending on the truss layout; offices,
walkways, heaters, utilities, etc. can be
located off the floor.
Clear Space. Clear space is that space
from 8 feet above the floor to the
ceiling. Install mezzanines, racks,
overhead conveyors, etc. in this area.
3
The Shell Game
WAS
NOW
OPEN
OPEN
It is easier to move equipment into an open area rather that
try and rearrange in place and meet production schedules.
4
Site Types

Brown Field – A previously developed parcel




Typically have incentives (tax, development,
economic growth, etc.) attached to them
Existing facility usually present
Watch for contamination (chemical, oils, etc.)
Green Field – Untouched parcel of property


Allows for “new” layout
Can have incentives attached for their
development
5
Relocation Assistance





Local Economic Development entities
State Department of Economic Development
Federal programs (Worker training, Welfare to
work Program, Enterprise Zones, etc.)
Local city assistance (Internal Revenue Bonds
– IRB, low cost loans, etc.)
Missouri Enterprise Business Assistance
Center
6
Determining Building Size

Determine the total space requirements




Utilize a worksheet (Excel)
Include all aspects of the operation
Include outside areas (parking, shipping &
receiving maneuvering area) on the worksheet
Round up to the nearest “standard size”



100 x 100, 50 x 50, 40 x 40, and even 25 x 50
feet
Size refers to column spacing inside the facility
A 2-to-1 length to width ratio is desirable
(rectangle)
7
Total Space Requirement
Worksheet
Stations X
W
X
L
Manufacturing
A. Fabrication
Strip Shear
2
X
9.5
X
12
Chop Shear
4
X
7
X
13
Punch press
3
X
8
X
11
Press break
6
X
8
X
11
Roll former
1
X
6
X
18
Fabrication Total:
B. Spot weld
1
X
26
X
30
C. Paint
1
X
28
X
100
D. Assembly & P.O.
1
X
16
X
38
Subtotal
50 percent allowance (mostly aisles)
Manufacturing Total:
II. Production Services
Receiving--steel
13
X
25
Receiving--cartons
17
X
19
Stores
18
X
25
Warehouse
64
X
68
Shipping
20
X
20
Maintenance & tool room
(two people @ 400 sq ft each)
Utilities (estimate only)*
100
Production Services Area Total:
(aisles are included in each layout in this area)
III. Employee Services
Employee entrance
10
X
20
Locker room
(3.5 sq ft/employee x 50 employees)
Toilets
10
X
20
Cafeteria
(10 sq ft/employee X 50 employees)
Drinking fountain
(6 fountains X 15 sq ft each)
Medical Services
(first aid room only 10 X 10 feet)
Services Area Required Total:
IV. Office area
(11 people from organizational chart)
(11 people X 200 sq ft each)
Total Building Space
V. Outside Areas
Receiving, parking, and maneuvering area
Shipping, parking and maneuvering area
Employee parking (50 employees)
1.5 employees per parking space
250 sq ft/parking place (9-2)
50 employees
1.5 employees/spaces = 34 spaces
34 spaces X 250 sq ft/space = 8,500 sq ft
Square Feet
I.
228
364
264
528
108
1,492
780
2,800
608
5,680
2,840
8,520
325
323
450
4,352
400
800
6,750
200
175
200
500
90
100
1,265
2,200
18,735
* I didn't size it properly, but the error will be minimized by an educated guess. This is a very minor use of area.
8
Building Size Determination
Our example building needs to be 18,735 sq. ft. No one
would build this size building due to cost. We need to
establish the 2-to-1 ratio first.
Step 1Divide by 2
18,735 / 2 = 9367.5 sq. ft.
Step 2Square root
9367.5 sq. ft. = 97 ft.
Step 3Round to a
multiple of
25 & 50 ft.
97 ft. = 100 ft therefore (2-to-1) = 100 ft. x 200 ft.
9
Building Size Determination
At 100 x 200 ft., this is essentially two 100 x 100 ft.
areas. Total area is 20,000 sq. ft. A comparable
square building would need to be 137 x 137 ft.,
rounded to 150 x 150 or 22,500 sq. ft.
The 2-to-1 rule yields a space savings of 2,500 sq. ft.
Additionally, a square building tends to put an
employee farther from an emergency exit.
10
Dimensionless Block Diagram
With the starting size of the building known,
begin by developing the dimensionless block
diagram. Maintain the relationships between
the block diagrams and the final layout.
11
Area Allocation Procedure
1.
Establish the 100 x 200 ft. grid using graph
paper. Start with the walls and columns
only.
100
ft.
I
I
I
I
I
I
I
I
I
I
I
I
200 ft.
12
Area Allocation Procedure
2. Calculate the number of “squares” (400
square feet) needed by each department.
Department
Fabrication
Spot weld
Paint
Assembly
Sq. Ft.
2,238
1,170
4,200
912
Blocks
6
3
11
3
13
Area Allocation Procedure
3. Place the blocks into the area allocation layout
using the dimensionless block diagram as a
guide.
R
S
F
F
F
F
W
W
W
SW F
F
F
F
F
TR W
W
W
SW F
F
F
F
F
TR W
W
Ship
PO W
W
W
P
F
F
F
F
Assy
RR
LR
C
O
O
O
O
Util
O
O
1,300 sq. ft.
14
Area Allocation Procedure
4.
5.
Layout the internal walls or area
boundaries.
Present the layout and receive a final
approval.
Begin the detailed layout. Show all
equipment
and utility requirements.
15
Office Area Allocation


Procedure is similar to the manufacturing
layout
Use the organizational chart as a guide


Use 200 sq. ft. of space per person as a guide
i.e. 36 employees x 200 sq. ft. = 7,200 sq. ft.
7,200 sq. ft. / 2 = 3,600 sq. ft.
3,600 sq. ft. = 60 ft.
2-to-1 ratio = 60 ft. x 120 ft.
16